I'm now working on making some fill pieces for the gap at the console/dash as seen below:

The Stealth uses a contoured piece of plastic that is covered in carpet to fill in this area on both sides of the console. I can't use this because I have removed about 3/4" between where the top of the console butts up against the bottom of the dash. This was done to give me enough room to get the console to sit flat on top of the tunnel structure. On the Stealth the tunnel structure doesn't have to accommodate a gas tank and so it sits lower with respect to the dash. In any event this has changed the shape of the curve on the bottom of the console. I did use the Stealth dash piece as a template and through trial and error I was able to cut a piece of Masonite to match the new curve:

Another issue is that the console edge is not a strait line and is actually a compound curve. After a few test fits and a few nasty words a thought entered my head, yes believe it or not! I know that wood and drywall can be made to fit contours if they are soaked and allowed to dry in place so I figured what the heck and gave it a try. Here's the piece soaking in the tub:

I only let it sit in the warm water for a couple of minutes as I was worried that it would crumble if it sat too long. I dabbed it dry and placed it into position on the console and taped it in place:

I let it sit overnight to dry completely and after work had a look:


It held the curve exactly, and there was much rejoicing

[This message has been edited by Sourmug (edited 06-18-2007).]

Before I took it off the car I traced the outside edge onto another piece of Masonite to make a bottom. You can see the curve marked out on the pics above. Here's the bottom cut out and ready to be attached to the filler:

it was then glued on using a glue gun, sanded and then both sides of the assembled piece were coated with fiberglass resin:

Once dry, a layer of fiberglass mat was added to the inside only as I wanted the outside nice and smooth for the vinyl:

The excess glass was trimmed and the edges sanded and did a test fit:

It looked good so the piece was covered with vinyl:



And here it sits:

The other side is in progress.

Thanks
Nolan

[This message has been edited by Sourmug (edited 06-18-2007).]